Method and apparatus for the production of fuel-gas, syngas and other constituent gas species

ABSTRACT

A method for producing fuel gases includes the steps of: providing a pool of molten sodium carbonate and sodium hydroxide salts within a reactor; introducing water, in the form of steam, and at least one solid carbonaceous material into the pool of molten salts; reacting the water, the carbonaceous material and the molten salts at a pressure less than 13.89 MPa and at temperatures below 929° C. to produce an output stream containing methane, hydrogen, carbon monoxide and carbon dioxide. The carbonaceous material can be refuse-derived materials, sewer solids, coal and shredded discarded tires.

FIELD OF THE INVENTION

This invention relates, generally, to methods and apparatus for the production of gasses and, specifically, to systems and methods for the production of fuel-gas, syngas and other constituent gas species.

BACKGROUND OF THE INVENTION

Global energy production is largely hydrocarbon-based fuels (including petroleum products, natural gas, etc.), which have been and will remain a majority of the energy supply to satisfy energy demands. Alternative and renewable energy have become the “green” desire of energy producers to replace conventional energy production. Renewable and alternative energy research and development efforts have included the search for improved techniques, systems and methods for producing energy from renewable biomass or recycled waste carbonaceous matter. Contemporary research has also focused on potential new sources of energy as well as improvements in existing alternative energy sources. For example, efforts to improve solar technology, wind energy production, bio-fuel production and waste-to-energy production are all ongoing. However, as those of ordinary skill in the art will recognize, all of these efforts are met with various obstacles, some economical, some political, and some scientific.

Commencing with the present inventor(s), Bingham, et al. of the present invention, significant past effort has been focused by various associated inventor(s) beginning with U.S. Pat. No. 7,078,012 B2 July 2006 Bingham et al., U.S. Pat. No. 7,153,489 B2 December 2006 Bingham et al., U.S. Pat. No. 7,279,077 B2 October 2007 Bingham et al., U.S. Pat. No. 7,294,323 B2 November 2007 Klingler et al., U.S. Pat. No. 7,665,328 B2 February 2010 Bingham et al., U.S. Pat. No. 8,685,281 B2 April 2014 Bingham et al., U.S. 2013/0020232 Al1/2013 Turner et al., and U.S. 2013/0020236 Al1/2013 Turner et al. on carbonaceous materials, energy conversion, energy efficiency, very high process temperatures and pressures, and the optimal use of alternative and renewable resources in meeting the energy demands of mankind. To this end, prior art has been focused on alkaline metal reforming for the production of hydrogen; molten salt oxidation has been disclosed for total destruction of materials into carbon dioxide and water; molten salt partial oxidation has been disclosed for production of hydrogen and carbon dioxide.

SUMMARY OF THE INVENTION

The objective of the present invention is to provide new methods for producing energy, for improving energy extraction efforts, and for improving existing renewable and alternative energy processes and techniques so as to provide energy more efficiently, more abundantly, and in a more environmentally friendly manner.

The present invention is related to the production of gasses and provides systems and methods for the production of fuel-gas, syngas other constituent gas species. One embodiment of the present invention described herein includes a system and method that includes molten salt decomposition. The process is carried out within a range of temperatures and pressures that have been ignored by the prior art.

In accordance with one particular embodiment, a method of producing gas at reduced process parameters is provided. The method includes providing a pool of molten alkaline salts within a reactor. The alkaline salts are selected from a group that includes sodium carbonate and sodium hydroxide. The alkaline salt, water and a carbonaceous (i.e., carbon-containing) material is introduced into the reactor. The water, the carbonaceous material and the molten pool react to produce an output stream of fuel-gas, syngas and other constituent gas species. The main components of the output stream are methane, hydrogen, carbon monoxide and carbon dioxide. Any water in the output stream is preferably recycled back to the molten pool. The following dominant equilibrium equation is representative of the process:

10Na2CO3+NaOH+5C+10H2O <--->10Na2CO3+NaOH+2CO2+4H2+CH4+2CO+4H2O

The method envisions use of refuse-derived fuels, sewer solids, coal and shredded discarded tires as carbonaceous source materials which are introduced into the molten alkaline salt pool. It is further envisioned that unconditioned water be used as the oxidizer source. The method can further include other actions as extracting water from the reactor and recycling the water back to the molten pool within the reactor, extracting gasses, liquids and solids according to various criteria, and extracting heat energy from the separation process for use, for example, in heating the molten pool or other materials that are introduced into the molten pool.

The system can additionally include various control systems. For example, a control system can be associated with the water supply to maintain the water supply at a desired temperature, a desired pressure and a desired flow rate. Likewise, a control system would be associated with the carbonaceous supply at a desired inlet pressure and a desired flow rate. The control methods would maintain the combined system temperature of less than 929° C. and pressure less than 13.89 mega-pascals (MPa).

The system can also include separation systems to separate gasses, liquids and solids that are produced by the reactor. The separation system can be configured to extract water from the output and recycle the water back to the water supply. Additionally, soluble solids can be separated, dissolved in water and returned to molten pool.

Other various components and actions can be included in these methods and systems as described below and will be appreciated by those of ordinary skill in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of a molten salt decomposition system in accordance with a presently-preferred embodiment of the present invention.

PREFERRED EMBODIMENT OF THE INVENTION

Alternatively, the present invention is focused on molten salt decomposition of carbonaceous materials. The unique objective and purpose of molten salt decomposition disclosed in the present invention is to maximize the production of fuel-gasses, specifically, carbon monoxide, methane and hydrogen, etc. The present patent disclosure describes the production of fuel gases and, more particularly, to systems and methods for the production of fuel-gas, syngas and other constituent gas species from a wide variety of carbonaceous feedstocks, which may include refuse-derived materials, sewer solids, renewable sources such as plant matter, coal and shredded discarded tires. The process conditions are new and neither anticipated by the prior art nor obvious with respect thereto. As will be recognized by those of ordinary skill in the art, the present invention uses process parameters which are separate and apart from those of disclosed by the prior art.

One embodiment of the present invention described herein includes a system and method that includes molten salt decomposition of a spectrum of conventional, renewable and alternative energy resources. Indeed, one benefit of the present invention is that a wide range of carbonaceous feed materials can be decomposed into a more useful and environmentally-friendly energy sources. Combined with the molten salts, feed materials generally include an oxidizing material and some form of carbonaceous material. In one embodiment, the oxidizing component can include non-potable water and the carbonaceous material can include refuse-derived fuel, sewer solids, coal and shredded discarded tires. Refuse-derived fuels may be harvested from municipal solid waste sites.

In comparative reference to the most contemporaneous prior art illustrated in U.S. Pat. No. 8,685,281 B2, Bingham, et.al., the same inventor(s) and the present invention by Bingham, et.al, discloses new art herein, which is separate, apart, and distinct to the said prior art in the following ways:

In the preferred embodiment of the present patent, unlike the stated pressures of U.S. Pat. No. 8,685,281 B2 that require at least 13.9 MPa to operate according to its claims, the selected pressures specified with the present invention are designated at or below 13.89 MPa;

And unlike the stated operating temperatures of U.S. Pat. No. 8,685,281 B2 that require at least 930° C. to operate said invention according to its claims, the selected temperatures that are specified in the present invention are designated at or below 929° C.;

And unlike the stated sodium salt specified in U.S. Pat. No. 8,685,281 B2, the selected alkaline salts incorporated in the present invention can be selected from an array of alkaline salts including at least sodium carbonate and sodium hydroxide;

And unlike the specified conditioned water in U.S. Pat. No. 8,685,281 B2, the present invention specifies any unconditioned water that can be utilized in this process;

And unlike the specified chemical equation of stated equilibrium in U.S. Pat. No. 8,685,281 B2, the present invention specifies a significantly different process output and equation of equilibrium to produce fuel-gas, syngas and other constituent gas species. The process is outlined in FIG. 1.

Referring now to FIG. 1, a block diagram shows an overview of an alkaline metal-based molten salt decomposition system 100 and related processes. The system 100 includes numerous subsystems or sub-processes which will be described in further detail herein. The first subsystem or sub-process includes a water supply 200. The system or process associated with the water supply 200 can include various water storage and recycling processes within the system 100. Associated with the water supply 200 is a water feed 250 process or system. As indicated by feedback line 102A, the water feed 250 can recycle water back to the water supply 200. As indicated by feedback line 102B, water is recycled back to water supply 200. Feedback line 102A and 102B are combined as feedback line 102. The system 100 also includes a carbonaceous material source 300 that will accept, store and prepare carbonaceous materials to be used within the system. Associated with the carbonaceous material source 300 is a carbonaceous material feed 350 process or system. As indicated by feedback line 103, the carbonaceous material feed 350 can recycle carbonaceous material back to the carbonaceous material supply 300. The water feed 250 and carbonaceous material feed 350 provide the materials needed to carry out desired chemical reactions to the reactor 104 and is introduced into reactor 104 through feed lines 105 and 106A. Additionally, water can be introduced into reactor 104 through feed line 106B. The reactor 104 can include process or system control functions for reactor conditioning 400 and process or system control functions for molten pool conditioning 500. Additional water can be introduced into 500 through feed line 106C to facilitate the conditioning of the molten pool. Undesired solids can be extracted 525 and removed from the reactor process. Likewise, undesired liquids can be extracted 550 and removed from the reactor process. The products exiting the reactor 104 can be subjected to various processes or systems such as product phase separation 600, solids extraction 700, and gas cleanup 800. It is noted that, while shown as distinct processes or systems, the separation processes can be intertwined and some of these processes can take place within the reactor 104 while not shown as such in FIG. 1. The following dominant equilibrium equation is representative of the process:

10Na2CO3+NaOH+5C+10H2O<--->10Na2CO3+NaOH+2CO2+4H2+CH4+2CO+4H2O

Unlike the prior U.S. Pat. No. 8,685,281 B2 invention, the present invention does not require recirculation of product solids extraction, product conditioning and product recycle to achieve the purposes of the present invention. In contrast, the present invention uses its reduced set of specifications and processes to simplify the handling of un-reacted solid carbonaceous materials.

Furthermore, it is not obvious from the prior art vis-à-vis the currently disclosed schema as to the purpose and implementation of the reduced specifications and changed process parameters discovered, disclosed and claimed in the present invention to achieve the objectives and beneficial methods disclosed in the claims.

Although only a single embodiment of the method and apparatus for the production of fuel-gas, syngas and other constituent gas species is shown and described, it will be obvious to those having ordinary skill in the art that changes and modifications can be made thereto without departing from the scope and the spirit of the invention as hereinafter claimed. 

What is claimed is:
 1. A method of producing gas by decomposition, the method comprising the steps of: providing a molten pool of alkaline salts, including sodium carbonate and sodium hydroxide, within a reactor; introducing an oxidizing material into the molten pool; introducing a carbonaceous material into the molten pool; reacting the oxidizing material, the carbonaceous material and the molten pool at a temperature less than 929° C. to produce an output stream of methane and other constituent gas species.
 2. The method of claim 1, wherein the oxidizing material, the carbonaceous material and the molten salts are reacted at a pressure less than 13.89 MPa.
 3. The method of claim 1, wherein the oxidizing material is water in the form of steam.
 4. The method of claim 3, wherein the alkaline salts, the carbonaceous material and the steam react in accordance with the following dominant equilibrium equation: 10Na2CO3+NaOH+5C+10H2O<--->10Na2CO3+NaOH+2CO2+4H2+CH4+2CO+4H2O
 5. The method of claim 1, wherein the output stream further comprises hydrogen, carbon monoxide, carbon dioxide, water vapor, and entrained non-gases.
 6. The method of claim 5, which further comprises the steps of: separating individual gases from the output stream; extracting water from the output stream and recycling it back to the molten pool of alkaline salts; separating any entrained non-gases from the output stream; and separating any water-soluble material from the non-gases and returning the water soluble materials back to the molten pool of alkaline salts.
 7. The method of claim 1, wherein the carbonaceous materials are selected from the group consisting of refuse-derived materials, sewer solids, coal and shredded discarded tires.
 8. A method of producing gas by decomposition, the method comprising the steps of: providing a molten pool of alkaline salts including sodium carbonate and sodium hydroxide within a reactor; introducing an oxidizing material into the molten pool; introducing a carbonaceous material into the molten pool; reacting the oxidizing material, the carbonaceous material and the molten pool at a pressure less than 13.89 MPa. to produce an output stream of methane and other constituent gas species.
 9. The method of claim 8, wherein the oxidizing material, the carbonaceous material and the molten salts are reacted at a temperature less than 929° C.
 10. The method of claim 8, wherein the oxidizing material is water in the form of steam.
 11. The method of claim 10, wherein the alkaline salts, the carbonaceous material and the steam react in accordance with the following dominant equilibrium equation: 10Na2CO3+NaOH+5C+10H2O<--->10Na2CO3+NaOH+2CO2+4H2+CH4+2CO+4H2O
 12. The method of claim 8, wherein the output stream further comprises hydrogen, carbon monoxide, carbon dioxide, water vapor, and entrained non-gases.
 13. The method of claim 12, which further comprises the steps of: separating individual gases from the output stream; extracting water from the output stream and recycling it back to the molten pool of alkaline salts; separating any entrained non-gases from the output stream; and separating any water-soluble material from the non-gases and returning the water soluble materials back to the molten pool of alkaline salts.
 14. The method of claim 8, wherein the carbonaceous materials are selected from the group consisting of refuse-derived materials, sewer solids, coal and shredded discarded tires.
 15. A method for producing carbonaceous fuel gas by decomposition, the method comprising the steps of: providing a pool of molten sodium carbonate and sodium hydroxide salts within a reactor; introducing water, in the form of steam, and at least one solid carbonaceous material into the pool of molten salts; reacting the water, the carbonaceous material and the molten salts at a pressure less than 13.89 MPa to produce an output stream containing methane and other gaseous species.
 16. The method of claim 15, wherein the reaction of the water, the carbonaceous material and the molten salts proceeds in accordance with the following dominant equilibrium equation: 10Na2CO3+NaOH+5C+10H2O<--->10Na2CO3+NaOH+2CO2+4H2+CH4+2CO+4H2O
 17. The method of claim 15, wherein the reaction of the water, the carbonaceous material and the molten salts proceeds at a temperature of less than 929° C.
 18. The method of claim 15, wherein the output stream further comprises hydrogen, carbon monoxide, carbon dioxide, water vapor, and entrained non-gases.
 19. The method of claim 18, which further comprises the steps of: separating individual gases from the output stream; extracting water from the output stream and recycling it back to the molten pool of alkaline salts; separating any entrained non-gases from the output stream; and separating any water-soluble material from the non-gases and returning the water soluble materials back to the molten pool of alkaline salts.
 20. The method of claim 15, wherein the carbonaceous materials are selected from the group consisting of refuse-derived materials, sewer solids, coal and shredded discarded tires. 